Packaging Performance Tests — Section 6.3

IATA DGR Section 6.3 — UN specification packaging performance tests. Each test has different severity levels depending on Packing Group (PG I/II/III). All tests are performed sequentially on the same specimen: drop → leak → hydrostatic → stack. Air transport without UN-approved packaging is not permitted (except LQ and EQ exemptions).

Test Sequence and General Rules

Sequential Testing

Tests are performed sequentially on the same specimen. The most critical test is applied first (drop), followed by leakproofness, hydrostatic, and stacking. Failure at any stage invalidates the entire test series.

Specimen Count

Minimum 5 specimens per test. Different drop orientations (flat, corner, edge) are tested on separate specimens. Type approval must be obtained before mass production begins.

PG Severity Hierarchy

PG I

Most stringent

Great danger

PG II

Medium

Medium danger

PG III

Least stringent

Minor danger

6.3.2

Drop Test

Measures the packaging's resistance to drop impacts encountered during normal transport. The most critical test — primary indicator of packaging integrity.

Procedure

1Package is filled to normal capacity (solid or liquid)
2Dropped onto a rigid, flat, unyielding surface (concrete/steel plate)
3Each specimen is dropped in a different orientation: flat, corner, edge
4Minimum 5 specimens required: 3 different orientations + 2 spares
5Temperature: -18°C (cold resistance) and ambient temperature tested separately

Criteria (Packing Group)

Packing Group I

1.8 m height

Packing Group II

1.2 m height

Packing Group III

0.8 m height

Pass / Fail Conditions

PASS: No structural breakage, no content leakage

PASS: Closure/cap remains in place, seal integrity maintained

FAIL: Any content leakage detected (even 0.5 mL)

FAIL: Structural crack or deformation — unsuitable for reuse

6.3.3

Leakproofness Test

Verifies the air/gas tightness of liquid-content packaging. Essential for air transport where pressure changes during flight are inevitable.

Procedure

1Package is sealed empty (closure and cap fitted)
2Internal pressure of 20 kPa (0.2 bar) is applied — using air or inert gas
3Held under pressure for 5 minutes continuously
4Submersion method: Package immersed in water tank, checked for air bubbles
5Alternative: Pressure decay method — pressure monitored via manometer

Criteria (Packing Group)

All PG

Minimum 20 kPa internal pressure

Duration

5 minutes uninterrupted

Temperature

Ambient (20-25°C)

Pass / Fail Conditions

PASS: No pressure loss for 5 minutes, no bubbles observed

PASS: No leakage at closure/cap connection points

FAIL: Air bubbles or pressure drop detected at any point

FAIL: Pressure drop > 5% — package is rejected

6.3.4

Hydraulic Pressure Test

Measures the packaging's resistance to internal pressure. Simulates package swelling when cabin pressure drops at flight altitude.

Procedure

1Package is completely filled with water
2Closure is sealed and pressure connection is attached
3Specified pressure is applied for 5 minutes (per PG level)
4Pressure increase must be gradual — no sudden pressurisation
5Deformation and leakage are observed during the test

Criteria (Packing Group)

Packing Group I

250 kPa (2.5 bar)

Packing Group II

100 kPa (1.0 bar)

Packing Group III

100 kPa (1.0 bar)

Pass / Fail Conditions

PASS: No leakage under pressure, no permanent deformation

PASS: Closure connection integrity maintained

FAIL: Water leakage detected from any point

FAIL: Permanent swelling or deformation > 1% volume increase

6.3.5

Stacking Test

Verifies that lower-layer packages can withstand the weight of packages stacked above. Simulates warehouse and cargo hold stacking conditions.

Procedure

1Package is filled to normal capacity
2Calculated load is applied on top (gross mass x stacking height factor)
3Load is maintained for 24 hours continuously
4Minimum load = gross mass x (stacking height / package height) x 1.8 safety factor
5Temperature: 40°C and 80% humidity (accelerated test conditions)

Criteria (Packing Group)

All PG

24-hour duration

Load calculation

Gross mass x stacking factor x 1.8

Stacking height

Typical: 3 m (5-6 layers in warehouse)

Pass / Fail Conditions

PASS: Height reduction (deformation) < 10%

PASS: No content leakage, closure connection intact

FAIL: Deformation > 10% — structural collapse risk

FAIL: Content leakage or closure opening

6.3.6

Vibration Test

Simulates vibration effects during transport. Mandatory for IBC and large packagings. Optional but recommended for standard packagings.

Procedure

1Package is secured to vibration table
2Vibration is applied for 1 hour at specified frequency range
3Frequency: 1-200 Hz sinusoidal sweep (or random profile)
4Amplitude: Level simulating normal road/air transport conditions
5Leakproofness and structural integrity are checked after the test

Criteria (Packing Group)

IBC

Mandatory — 1 hour

Large packaging

Mandatory — 1 hour

Standard packaging

Optional (recommended)

Pass / Fail Conditions

PASS: No leakage after vibration

PASS: Closure/cap not loosened, labels undamaged

FAIL: Content leakage or closure loosening

FAIL: Structural crack or weld breakage

Summary Table — Test Parameters by PG

Test	PG I	PG II	PG III
Drop Test	1.8 m	1.2 m	0.8 m
Leakproofness	20 kPa, 5 min (all PG)
Hydraulic Pressure	250 kPa	100 kPa	100 kPa
Stacking	24 hours, deformation < 10% (all PG)
Vibration	1 hour (IBC/large mandatory, standard optional)

References

• IATA DGR 67th Ed Section 6.3 (Performance Testing)
• UN Model Regulations Rev. 22+ Chapter 6.1 (Orange Book)
• ISO 2206 — Packaging Drop Test
• ISO 2233 — Packaging Stacking Test
• ISO 2872 — Packaging Vibration Test